1998 ISUZU TROOPER Remove engine

6A±88
ENGINE MECHANICAL
015RW001
4. Install flywheel
1. Thoroughly clean and remove the oil from the
threads of crankshaft.
2. Remove the oil from the crankshaft and flywheel
mounting faces.
3. Mount the flywheel on the crankshaft and then
install the washer.
4. Holding the crankshaft stationary, tighten the
flywheel bolts in the order shown.
Torque: 54 N´m (5.5 Kg´m/40 lb ft)
NOTE: Do not reuse the bolts and do not apply oil or
thread lock to the bolts.
015RS018
5. Install piston and connecting rod assembly.

Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaft pins.
NOTE: Do not apply engine oil to the bearing back faces.
Check to see that the piston ring end gaps are
correctly positioned.
015RS019
Legend
(1) No.1 Compression Ring
(2) No.2 Compression Ring
(3) Oil Ring Side Rail Upper
(4) Oil Ring Side Rail Lower
(5) Piston Front Mark

Insert the piston/connecting rod assemblies into
each cylinder with the piston ring compressor.

The front marks (1) must be facing the front of the
engine.
015RS020
6. Install oil gallery and tighten the bolts in 2 steps in the
order shown.
1st step : 29 N´m (3.0 Kg´m/22 lb ft)
2nd step : 55
~ 65

6A±89
ENGINE MECHANICAL
012RS007
7. Install cylinder block side bolts (1) and tighten
crankcase bolts in sequence shown in the illustration.
Torque : 39 N´m (4.0 Kg´m/29 lb ft)
012RW005
8. Install oil pump assembly. Refer to ªOil Pumpº in this
manual.
9. Install oil strainer and O-ring.
10. Install oil pipe and O-ring.
11. Install crankcase with oil pan.
1. Completely remove all residual sealant, lubricant
and moisture from the sealing surfaces. The
surfaces must be perfectly dry.
2. Apply a correct width bead of sealant (TB± 1207C
or its equivalent) to the contact surfaces of the
crankcase. There must be no gaps in the bead.
3. The oil pan must be installed within 5 minutes
after sealant application to prevent premature
hardening of sealant.
4. Tighten the bolts and nuts to the specified torque.
Torque : 10 N´m (1.0 Kg´m/89 lb in)
013RW010
Legend
(1) Portion Between Both Holes
(2) Bolt Hole Portions
12. Install cylinder head gasket.
13. Install cylinder head assembly. Refer to ªCylinder
Headº in this manual.

6A±96
ENGINE MECHANICAL
Special Tool
ILLUSTRATIONTOOL NO.
TOOL NAME
5±8840±0011±0
(J±21687±02)
Remover; tie rod end
5±8840±2441±0
Set Number of Valve
Compressor
5±8840±2446±0
(J±8062)
Compressor; Valve
Spring (1)
5±8840±2547±0
(J±42898)
Adapter; Compressor
Valve Spring (2)
5±8840±0623±0
(J±37281)
Remover; Oil controller
5±8840±0624±0
(J±38537)
Installer; Oil controller
5±8840±2445±0
(J±42985)
Installer; Camshaft oil
seal
5±8840±2545±0
(J±39206)
Installer; Pilot bearing
ILLUSTRATIONTOOL NO.
TOOL NAME
5±8840±0133±0
(J±8614±01)
Holder; Crankshaft
5±8840±2153±0
(J±37228)
Seal cutter
5±8840±2286±0
(J±39201)
Installer; Real oil seal
9±8511±4209±0
(J±24239±1)
Cylinder head bolt
wrench
5±8840±2442±0
(J±42899)
Replacer; Valve guide
(set) (1,2)
5±8840±2548±0
(J±42687)
Installer; Valve guide (1)
5±8840±2549±0
(J±37985±1)
Remover; Valve guide
(2)
5±8840±2444±0
(J±42689)
Adjusting Tool: Valve
clearance

6B±6
ENGINE COOLING
Draining and Refilling Cooling
System
Before draining the cooling system, inspect the system
and perform any necessary service to ensure that it is
clean, does not leak and is in proper working order. The
engine coolant (EC) level should be between the ªMINº
and ªMAXº lines of reserve tank when the engine is cold.
If low, check for leakage and add EC up to the ªMAXº line.
There should not be any excessive deposit of rust or
scales around the radiator cap or radiator filler hole, and
the EC should also be free from oil.
Replace the EC if excessively dirty.
1. Completely drain the cooling system by opening the
drain plug (2) at the bottom of the radiator.
110RW002
2. Remove the radiator cap.
WARNING: T O AV O I D T H E D A N G E R O F B E I N G
BURNED, DO NOT REMOVE THE CAP WHILE THE
ENGINE AND RADIATOR ARE STILL HOT.
SCALDING FLUID AND STEAM CAN BE BLOWN OUT
UNDER PRESSURE.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with
soap and water. Flush it well with clean water, then
drain it. Install the reserve tank and hoses.
4. Refill the cooling system with the EC using a solution
that is at least 50 percent antifreeze but no more than
70 percent antifreeze.
5. Fill the radiator to the base of the filler neck.
Fill the EC reserve tank to ªMAXº line when the engine
is cold.
6. Block the drive wheels and firmly apply the parking
brake. Shift an automatic transmission to ªPº (Park)
or a manual transmission to neutral.
7. Remove the radiator cap. Start the engine and warm
it up at 2,500 ~ 3,000 rpm for about 30 minutes.
8. When the air comes out from the radiator filler neck
and the EC level has gone down, replenish with the
EC. Repeat this procedure until the EC level does not
go down. Then stop the engine and install the radiator
cap. Let the engine cool down.9. After the engine has cooled, replenish with EC up to
the ªMAXº line of the reserve tank.
10. Start the engine. With the engine running at 3,000
rpm, make sure there is no running water sound from
the heater core (behind the center console).
11. If the running water sound is heard, repeat steps 8 to
10.

ENGINE COOLING6B±7
Water Pump
Water Pump and Associated Parts
030RS002
Legend
(1) Timing Belt
(2) Idle Pulley(3) Water Pump Assembly
(4) Gasket
Removal
1. Disconnect battery ground cable.
2. Drain coolant.
3. Radiator hose (on inlet pipe side).
4. Remove timing belt. Refer to ªTiming Beltº in this
manual.
5. Remove Idle pulley.
6. Remove water pump assembly.
7. Remove gasket.
Inspection
Make necessary repair and parts replacement if extreme
wear or damage is found during inspection. Should any of
the following problems occur, the entire water pump
assembly must be replaced:

Crack in the water pump body

EC leakage from the seal unit

Play or abnormal noise in the bearing

Cracks or corrosion in the impeller.
Installation
1. Install gasket, clean the mating surface of gasket
before installation.2. Install water pump assembly and tighten bolts to the
specified torque.
Torque: 25 N´m (2.5 Kg´m/18 lb ft)

Tightening order
The tightening order are in the illustrate.
NOTE: To prevent the oil leakage, apply the LOCTITE
262 or an equivalent, to the arrow marked fixing bolt
thread.
030RW008

6B±8
ENGINE COOLING
3. Idle pulley

Install idle pulley and tighten bolt to the specified
torque.
Torque: 52 N´m (5.3 Kg´m/38 lb ft)4. Timing belt

Install timing belt. Refer to timing belt installation
step in ªTiming Beltº in this manual.
5. Connect radiator inlet hose and replenish EC.
6. Connect battery ground cable.
Thermostat
Thermostat and Associated Parts
031RW001
Legend
(1) Thermostat Housing
(2) Thermostat
(3) Outlet Pipe
Removal
1. Disconnect battery ground cable.
2. Drain engine coolant from the radiator and engine.
3. Disconnect radiator hose from the inlet pipe.
4. Remove thermostat housing.
5. Remove thermostat(2).
Inspection
Suspend the thermostat in a water±filled container using
thin wire. Place a thermometer next to the thermostat.
Do not directly heat the thermostat.
Gradually increase the water temperature. Stir the water
so that the entire water is same temperature.
031RS003Confirm the temperature when the valve first begins to
open.
Valve opening temperature 74.5C ~ 78.5
C
(166.1
F ~ 173.3
F)
Confirm the temperature when the valve is fully opened.
Valve full open temperature and lift More than
8.5mm (0.33 in) at 90
C (194
F)
Make necessary repair and parts replacement if extreme
wear or damage is found during inspection.
Installation
1. Install thermostat into the outlet pipe(4) making sure
that the air hole is in the up position.
2. Install thermostat housing and tighten bolts to the
specified torque.
Torque: 25 N´m (2.5 Kg´m/18 lb ft)
3. Installation rubber hose.
4. Replenish engine coolant (EC).
5. Start engine and check for EC leakage.

ENGINE COOLING6B±9
Radiator
Radiator and Associated Parts
110RW003
Legend
(1) Oil Cooler Hose For Automatic Transmission
(2) Radiator Hose
(3) Fan Guide, Lower(4) Reserve Tank Hose
(5) Bracket
(6) Radiator Assembly
(7) Reserve Tank
Removal
1. Disconnect battery ground cable.
2. Loosen a drain plug(2) to drain EC.
3. Disconnect oil cooler hose(1) on automatic
transmission (A/T).
4. Disconnect radiator inlet hose and outlet hose from
the engine.
110RW002
5. Remove fan guide(1), clips(3) on both sides and the
bottom lock, then remove lower fan guide(3) with fan
shroud(4).
110RW001

6B±10
ENGINE COOLING
6. Disconnect the reserve tank hose(4) from radiator.
7. Remove bracket(5).
110RW004
8. Lift up and remove the radiator assembly with hose,
taking care not to damage the radiator core with a fan
blade.
9. Remove rubber cushions on both sides at the bottom.
Inspection
Radiator Cap
Measure the valve opening pressure of the pressurizing
valve with a radiator filler cap tester.
Replace the cap if the valve opening pressure is outside
the standard range.
Valve opening pressure kPa (psi) 88.3 ~ 117.7
(12.8 ~17.1)
Cap tester: 5±8840±0277±0
Adapter: 5±8840±2603±0
Check the condition of the vacuum valve in the center of
the valve seat side of the cap. If considerable rust or dirt is
found, or if the valve seat cannot be moved by hand, clean
or replace the cap.Valve opening vacuum kPa (psi) 1.96 ~ 4.91
(0.28 ~ 0.71)
110RS006
Radiator Core
1. A bent fin may result in reduced ventilation and
overheating may occur. All bent fins must be
straightened. Pay close attention to the base of the fin
when it is being straightened.
2. Remove all dust, bugs and other foreign material.
Flushing the Radiator
Thoroughly wash the inside of the radiator and the engine
coolant passages with cold water and mild detergent.
Remove all signs of scale and rust.
Cooling System Leakage Check
Use a radiator cap tester to force air into the radiator
through the filler neck at the specified pressure of 196 kPa
(28.5 psi) with a cap tester:

Leakage from the radiator

Leakage from the coolant pump

Leakage from the water hoses

Check the rubber hoses for swelling.